Method of constructing a solar array module

Abstract

The present invention is directed to a method of constructing a solar array wall module (10). The general steps involved in this method comprise: 1. constructing a structural backbone (12) in the form of a wall (14) wherein (a) a plurality of elongate building panels such as (16a) to (16f) are interconnected in a side-by-side relationship, and (b) a pair of cross-bracing members (18a) and (18b) are connected at respective of opposing ends of the interconnected building panels (16a) to (16f); 2. mounting a plurality of solar panels such as (20a) to (20I) and (22a) to (22I) across opposing of respective faces of the wall (14) of the structural backbone (12) thereby forming the solar array wall module (10). It is to be understood that construction of the structural backbone (12) and mounting of the solar panels such as (20a) to (20I) occurs at ground level with the structural backbone (12) in a general horizontal disposition. In the illustrated embodiment where solar panels are mounted to both faces of the structural backbone (12) the solar array wall module (10) is formed in a bifacial solar arrangement.

Description

METHOD OF CONSTRUCTING A SOLAR ARRAY MODULE Technical Field

[0001] The present invention is broadly directed to a method of constructing a solar array wall module. The invention is more specifically directed to a method of constructing and erecting multiple solar array wall modules in a solar wall farm. The invention is also broadly directed to a solar array wall module.Background of Invention

[0002] Conventional solar photovoltaic installations are predominantly mounted in horizontal or inclined orientations and occupy substantial ground area, often limiting alternative land use such as agriculture. Large-scale installations also present construction and safety challenges, particularly where solar panels must be installed at height. In an attempt to address these shortcomings with conventional solar installations, there exist vertically-oriented PV systems including mounting posts and associated framework. These systems use bifacial PV panels and for stability require robust footings or other steel reinforced concrete foundation.Summary of Invention

[0003] According to a first aspect of the present invention there is provided a method of constructing a solar array wall module, said method comprising:constructing a structural backbone in the form of a wall wherein (i) a plurality of elongate building panels are interconnected in a side-by-side relationship, and (ii) one or more cross-bracing members are connected at or adjacent at least one end of the interconnected building panels;mounting a plurality of solar panels across at least one face of the wall of the structural backbone thereby forming the solar array wall module.

[0004] Preferably the method also comprises erecting the solar array wall module into a vertical disposition. Alternatively said method also comprises erecting the structural backbone or wall into the vertical disposition and thereafter mounting the plurality of solar panels to form the solar array wall module.

[0005] Preferably the method further comprises stabilising the solar array wall module or the wall of the structural backbone in the vertical disposition. More preferably said stabilising of the module or the wall involves installation of a plurality of overhead cables, each anchored at a proximal end or opposing ends at ground level, and connected at a distal end or an intermediate part to an uppermost of the cross-bracing members. Still more preferably said anchoring of the proximal or opposing ends of the overhead cable is effected via ground anchorage driven into the ground, and an associated tensioning device for tensioning the overhead cable.

[0006] Preferably each of the building panels is of a generally channel-shaped cross section wherein said mounting of the solar panels to the wall of the structural backbone creates an elongate void between the channel-shaped building panel and one or more of the solar panels. More preferably the solar panels are mounted in contact with opposing ridges of one or neighbouring of the channel-shaped building panels wherein said elongate void is one of a plurality of chimneys corresponding to respective of the plurality of channels of the building panels.

[0007] Preferably said erecting of the wall structure involves driving at least part of the interconnected building panels into the ground. More preferably the structural backbone or wall includes a lowermost of the cross-bracing members connected in a spaced relationship to an exposed end of the interconnected building panels wherein said driving of the building panels involves burying said exposed end of said panel in the ground at or around a level of the lowermost cross-bracing member.

[0008] Preferably the solar array wall module is one of a plurality of said solar wall modules wherein said method involves erecting the plurality of modules in the vertical disposition in substantial alignment with one another thereby form a row of said solar wall modules. More preferably said method also involves erecting said module in parallel and spaced-apart rows thereby forming a solar wall farm.

[0009] Preferably the spaced-apart rows of solar wall modules are separated a minimum distance permitting passage of farming equipment. More preferably the parallel rows of solar wall modules are formed at a minimum height wherein the associated overhead cables are at a height between neighbouring of the rows sufficient for passage of farming equipment.

[0010] Preferably said mounting of the solar panels to the wall of the structural backbone involves mounting said panels to both faces of said backbone for forming the solar array wall module in a bifacial solar arrangement.

[0011] According to a second aspect of the present invention there is provided a solar array wall module comprising:a structural backbone in the form of a wall including:(a) a plurality of elongate building panels interconnected in a side-by-side relationship,(b) one or more cross-bracing members connected at or adjacent at least one end of the interconnected building panels;a plurality of solar panels mounted across at least one face of the wall of the structural backbone thereby forming the solar array wall module.

[0012] Preferably the solar array wall module also comprises a plurality of overhead cables arranged to cooperate with said module or the wall of the structural backbone to stabilise it in the vertical disposition. More preferably each of the overhead cables is operatively coupled to a ground anchorage and an associated tensioning device for anchoring and tensioning of the corresponding cable.

[0013] Preferably each of the building panels is of a generally channel-shaped cross section wherein the solar panels and an associated of the channel-shaped building panels forms an elongate void. More preferably said solar panels are mounted in direct contact with opposing ridges of one or neighbouring of the channelshaped building panels forming one of a plurality of chimneys corresponding to respective of the plurality of channels of the building panels. Even more preferably a lowermost of the solar panels is mounted to the backbone in a spaced relationship to an end of said backbone thereby forming a side-facing opening for entry to a corresponding of the chimneys.

[0014] Preferably the solar array wall module is one of a plurality of said modules erected in the vertical disposition in alignment with one another in a row of said modules. More preferably the row of said modules is one of a plurality of parallel rows together forming a solar wall farm.Brief Description of Drawings

[0015] In order to achieve a better understanding of the nature of the present invention a preferred embodiment of a method of constructing a solar array wall module together with a solar array wall module itself will now be described, by way of example, with reference to the accompanying drawings in which:Figure 1 is a perspective view of part of a method of constructing a solar array wall module together with part of a structural backbone taken from the solar array wall module according to preferred embodiments of respective of first and second aspects of the invention;Figure 2 is a perspective view of the embodiment of figure 1 depicting the elongate building panels of the wall interconnected in a side-by-side relationship;Figure 3 is a perspective view of the preferred embodiments of both aspects depicting the interconnected building panels of figure 2 together with solar panels across both faces of the wall of the structural backbone;Figure 4 is a perspective view in detail taken from figure 3 depicting an enlarged representation of the preferred embodiment of the solar array wall module according to both aspects of the invention;Figure 5 is a schematic illustration of the preferred embodiment of the first aspect depicting erection of the solar array wall module of the preferred embodiment of figure 3;Figures 6 and 7 are schematic illustrations of the preferred embodiment of the solar array wall module of figures 3 to 5 of the second aspect in its vertical disposition; Figure 8 is a schematic illustration of the solar array wall module of the preferred embodiment of figures 6 and 7 of the second aspect depicting the chimney-type configuration;Figure 9 is a perspective view of an embodiment of a ground anchorage utilised in the method of the first aspect;Figures 10 and 11 are schematic illustrations of the preferred embodiment of the method of the first aspect utilising the ground anchorage of figure 9 together with overhead cables in stabilising the solar array wall module in the vertical disposition;Figure 12 is a schematic illustration of a solar wall farm including a plurality of rows of solar array wall modules of the preferred embodiment according to both aspects of the invention.Detailed Description

[0016] In a preferred embodiment of the first aspect of the invention there is a method of constructing a solar array wall module 10 as depicted in the illustrations of figures 1 to 5. The general steps involved in this embodiment of the method comprise:1. constructing a structural backbone 12 in the form of a wall 14 wherein (a) a plurality of elongate building panels such as 16a to 16f are interconnected in a side-by-side relationship, and (b) a pair of cross-bracing members 18a and 18b are connected at respective of opposing ends of the interconnected building panels 16a to 16f (see figures 1 and 2);2. mounting a plurality of solar panels such as 20a to 20I and 22a to 22I across opposing of respective faces of the wall 14 of the structural backbone 12 thereby forming the solar array wall module 10 (see figures 3 and 4).

[0017] It is to be understood that construction of the structural backbone 12 and mounting of the solar panels such as 20a to 20I occurs at ground level with the structural backbone 12 in a general horizontal disposition. In the illustrated embodiment where solar panels are mounted to both faces of the structural backbone 12 the solar array wall module 10 is formed in a bifacial solar arrangement. In the bifacial solar wall module 10, the structural backbone 12 may at ground level and in the horizontal disposition be clad with solar panels such as 20a to 20I on one face and thereafter (i) raised above ground level sufficient distance for solar cladding such as 22a to 22I an opposing or underlying face of the backbone 12, or (ii) raised into the vertical disposition and clad in the opposing solar panels 22a to 22I.

[0018] Figure 5 illustrates erection of the solar array wall module 10 into the vertical disposition using suitable farm machinery such as a utility tractor 25. In this embodiment the solar array wall module 10 in its assembled form is raised from its horizontal ground-level disposition by (a) connecting a pair of lifting stays such as 27a and 27b at opposing ends to respective of the tractor 25 and an uppermost of the cross-bracing members 18b, and (b) reversing the tractor 25 thereby tilting the solar array wall module 10 upward into the vertical disposition seen in figures 6 to 8. It is to be understood that while erecting the solar wall module 10 it is driven partly into the ground. In this embodiment a lowermost of the cross-bracing members 18a is spaced from an exposed end 26 of the interconnected building panels such as 16a to 16f. The building panels of the wall structure 14 are thus driven into the ground wherein the exposed end 26 is buried up to the level of the lowermost cross-bracing member 18a. It is to be understood that the wall structure 14 is driven into the ground under the combined effect of the pulling and tilting forces exerted by the tractor 25 together with the inherent weight of the solar wall module 10 itself.

[0019] Returning to figures 3 and 4, each of the building panels such as 16a to 16c is of a generally channel-shaped cross section wherein the mounting of the solar panels such as 20a and 20b to the wall 14 of the structural backbone 12 creates an elongate void such as 28a and 28b respectively. The elongate void such as 28a is formed between the channel-shaped building panel 16a and neighbouring of the solar panels 20a, 20d, 20g, 20j. The elongate void 28b is similarly formed between the corresponding channel-shaped building panel 16b and adjacent pairs of the neighbouring solar panels such as 20a / b, 20d / e, 20g / h, 20j / k. In the bifacial arrangement, the wall 14 or backbone 12 on an opposing face together with neighbouring panels such as 22a, 22d, 22g, 22j form an opposing elongate void such as 32a. It will be understood that the opposing elongate void 32a is formed by interconnected of the adjacent building panels 16a and 16b.

[0020] In this embodiment the solar panels such as 20a, 20d, 20g, 20j are mounted in contact with opposing ridges such as 34aa and 34ba of neighbouring of the building panels 16a and 16b. This means each of the adjacent elongate voids such as 28a and 28b are largely sealed from one another in the form of adjacent chimneys corresponding to respective of the channels such as 30a and 30b of the corresponding building panel 16a and 16b. It is to be understood that thesubstantially sealed elongate void such as 28a / b is effectively replicated on the opposing face of the structural backbone 12 or wall 14. In this bifacial arrangement, the opposing void or channel such as 32a is formed between adjacent of the opposing solar panels 22a, 22d, 22g, 22j and a channel 38a formed between adjoining of neighbouring of the channel-shaped building panels such as 16a and 16b.

[0021] In this embodiment lowermost of the solar panels such as 20a to 20c are mounted to the backbone 12 in a spaced relationship to a lowermost end of the wall 14. This construct forms a side-facing opening such as 40a for entry to the corresponding void or chimney 28a. On this face of the wall 14, the side-facing opening 40a is rectangular-shaped and formed between the lowermost cross-bracing member 18a and the lowermost solar panel 20a. It will be understood that in the bifacial arrangement there are likewise side-facing openings such as 42a (see figure 6) for entry to the corresponding void or chimney such as 32a. In operation with the solar wall module 10 in its vertical disposition, it is understood that the elongate voids or chimneys such as 28a and 32a create a cooling effect on the corresponding solar panels such as 20a / d / g / j and 22a / d / g / j. This cooling effect is enabled by the elongate voids or chimneys such as 28a and 32a wherein hot air rises upwardly through said chimneys 28a and 32a with cooler air being drawn in from respective of the chimney openings 40a and 42a at ground level. This continuous flow of cooling air improves efficiency of power conversion from the solar panels such as 20a to 20I which inherently perform better at lower temperatures.

[0022] As best seen in figures 10 and 11 , the method of this embodiment further comprises stabilising the solar array wall module such as 10aa in the vertical disposition. In this construct, stabilising of the module 10aa involves stabilising neighbouring of replica of the modules 10ab, 10ac, 10ad. This involves installation of a plurality of overhead cables such 46aa to 46fa interconnecting the neighbouring modules 10aa / ab / ac / ad wherein outermost of the cables 46aa / fa are each at opposing ends anchored at ground level via ground anchorages such as 48aa / fa and 48fa / fb respectively. Each of the overhead cables 46aa to 46fa is connected to uppermost of the cross-bracing members such as 18aa to 18ad of neighbouring of the modules 10aa to 10ad in their vertical disposition. In this example the outermost ofthe overhead cables 46aa and 46fa are associated with a tensioning device (not shown) for tensioning said cable 46aa / fa.

[0023] Figure 9 shows one of the ground anchorages 48aa taken from the installation of figures 10 and 11. The ground anchorage 48aa includes an elongate ground-engaging member 50aa between its ends being connection to a burial piece 52aa. In this embodiment the elongate member 50aa is constructed of a right-angle section steel welded to the burial piece 52aa in the form of an inverted triangularshaped plate. The ground anchorage 50aa is designed to be driven into the ground wherein the burial piece 52aa resides below ground level and functions to resist withdrawal of the anchorage 48aa. The elongate member 50aa located above ground is configured for connection to one of the outermost of the overhead cables such as 46aa or an associated tensioning device.

[0024] As seen in figure 12, the solar array module such as 10aa is one of a plurality of solar modules such as 10aa to 10ga erected in their vertical disposition in substantial alignment with one another thereby forming a row of said solar wall modules designated as 100a. The row of solar modules 100a is one of a plurality of rows such as 100a to 100d arranged in parallel and spaced relationship relatively to each other. The plurality of rows of solar wall modules 100a to 100d together form a solar wall farm 102. The spaced-apart rows of solar modules such as 100a and 100b are separated a minimum distance permitting passage of farming equipment such as the tractor 25. The parallel rows of solar wall modules such as 100a / b are also formed at a minimum height wherein the associated overhead cables such as 46aa to 46fa are at a height sufficient for passage of underlying farming equipment.

[0025] Figures 3 to 8 and figures 10 to 12 depict an embodiment of a solar array wall module 10 or 10aa of a second aspect of the invention. For ease of reference and to avoid repetition, like or similar components of the embodiments of the first and second aspects of the invention are designated with the same reference numeral. In this embodiment of the second aspect, the solar array wall module 10 broadly comprises:a structural backbone 12 in the form of a wall 14 including:(a) a plurality of elongate building panels such as 16a to 16f interconnected in a side-by-side relationship,(b) one more cross-bracing members such as 18a and 18b connected at opposing ends of the interconnected building panels 16a to 16f; a plurality of solar panels such as 20a to 20I and 22a to 22I mounted across opposing of respective faces of the wall 14 of the structural backbone 12 thereby forming the solar array wall module 10.

[0026] Now that embodiments of both aspects of the method of constructing a solar array wall module together with the module itself have been described it will be apparent to those skilled in the art that they present the following advantages:1. the solar array wall modules in their vertical orientation provide increased power generation compared with the equivalent footprint of a conventional solar farm with fixed horizontal or solar tracking installations;2. the construction methodology and modules enable construction at ground level facilitating a safe working environment;3. the building panels together with the cross-bracing members provide interconnected panels in the form of a structural backbone is suitably robust for direct mounting of solar panels;4. the structural backbone or wall permits solar panel cladding on both of its opposing faces creating the bifacial arrangement maximising conversion of sunlight to electricity;5. the structural backbone with or without solar panels is sufficiently robust for tilting or other actions in erecting the backbone or solar wall module into the vertical disposition;6. the method of construction eliminates any requirement for concrete footings or foundations enabling relatively quick construction and providing an environmentally friendly installation.

[0027] Those skilled in the art will appreciate that the invention as described herein is susceptible to variations and modifications other than those specifically described. For example, the structural backbone may be clad in full or part in its vertical disposition rather than the ground level cladding of the preferred embodiment. The design, shape and construct of the structural backbone may vary provided theresulting wall is adequately robust for cladding with solar panels and provides the necessary stability during its erection and whilst stabilised in the vertical disposition.

[0028] All such variations and modifications are to be considered within the scope of the present invention the nature of which is to be determined from the foregoing description.

Claims

Claims1. A method of constructing a solar array wall module, said method comprising:constructing a structural backbone in the form of a wall wherein (i) a plurality of elongate building panels are interconnected in a side-by-side relationship, and (ii) one or more cross-bracing members are connected at or adjacent at least one end of the interconnected building panels;mounting a plurality of solar panels across at least one face of the wall of the structural backbone thereby forming the solar array wall module.

2. A method as claimed in claim 1 also comprising erecting the solar array wall module into a vertical disposition.

3. A method as claimed in claim 1 also comprising erecting the structural backbone or wall into the vertical disposition and thereafter mounting the plurality of solar panels to form the solar array wall module.

4. A method as claimed in any one of the preceding claims further comprising stabilising the solar array wall module or the wall of the structural backbone in the vertical disposition.

5. A method as claimed in claim 4 wherein said stabilising of the module or the wall involves installation of a plurality of overhead cables, each anchored at a proximal end or opposing ends at ground level and connected at a distal end or an intermediate part to an uppermost of the cross-bracing members.

6. A method as claimed in claim 5 wherein said anchoring of the proximal or opposing ends of the overhead cable is effected via ground anchorage driven into the ground, and an associated tensioning device for tensioning the overhead cable.

7. A method as claimed in any one of the preceding claims wherein each of the building panels is of a generally channel-shaped cross section wherein said mounting of the solar panels to the wall of the structural backbone creates an elongate void between the channel-shaped building panel and one or more of the solar panels.

8. A method as claimed in claim 7 wherein the solar panels are mounted in contact with opposing ridges of one or neighbouring of the channel-shaped buildingpanels wherein said elongate void is one of a plurality of chimneys corresponding to respective of the plurality of channels of the building panels.

9. A method as claimed in either of claims 2 or 3 wherein said erecting of the wall structure involves driving at least part of the interconnected building panels into the ground.

10. A method as claimed in claim 9 wherein the structural backbone or wall includes a lowermost of the cross-bracing members connected in a spaced relationship to an exposed end of the interconnected building panels wherein said driving of the building panels involves burying said exposed end of said panel in the ground at or around a level of the lowermost cross-bracing member.

11. A method as claimed in any one of the preceding claims wherein the solar array wall module is one of a plurality of said solar wall modules wherein said method involves erecting the plurality of modules in the vertical disposition in substantial alignment with one another thereby form a row of said solar wall modules.

12. A method as claimed in claim 11 also involving erecting said module in parallel and spaced-apart rows thereby forming a solar wall farm.

13. A method as claimed in claim 12 wherein the spaced-apart rows of solar wall modules are separated a minimum distance permitting passage of farming equipment.

14. A method as claimed in either of claims 12 or 13 (when dependent on either of claims 5 or 6) wherein the parallel rows of solar wall modules are formed at a minimum height wherein the associated overhead cables are at a height between neighbouring of the rows sufficient for passage of farming equipment.

15. A method as claimed in any one of the preceding claims wherein said mounting of the solar panels to the wall of the structural backbone involves mounting said panels to both faces of said backbone for forming the solar array wall module in a bifacial solar arrangement.

16. A solar array wall module comprising:a structural backbone in the form of a wall including:(a) a plurality of elongate building panels interconnected in a side-by-side relationship,(b) one or more cross-bracing members connected at or adjacent at least one end of the interconnected building panels;a plurality of solar panels mounted across at least one face of the wall of the structural backbone thereby forming the solar array wall module.

17. A solar array wall module as claimed in claim 16 also comprising a plurality of overhead cables arranged to cooperate with said module or the wall of the structural backbone to stabilise it in the vertical disposition.

18. A solar array wall module as claimed in claim 17 wherein each of the overhead cables is operatively coupled to a ground anchorage and an associated tensioning device for anchoring and tensioning of the corresponding cable.

19. A solar array wall module as claimed in any one of claims 16 to 18 wherein each of the building panels is of a generally channel-shaped cross section wherein the solar panels and an associated of the channel-shaped building panels forms an elongate void.

20. A solar array wall module as claimed in claim 19 wherein said solar panels are mounted in direct contact with opposing ridges of one or neighbouring of the channelshaped building panels forming one of a plurality of chimneys corresponding to respective of the plurality of channels of the building panels.

21. A solar array wall module as claimed in either of claims 19 or 20 wherein a lowermost of the solar panels is mounted to the backbone in a spaced relationship to an end of said backbone thereby forming a side-facing opening for entry to a corresponding of the chimneys.

22. A solar array wall module as claimed in any one of claims 16 to 21 wherein the solar array wall module is one of a plurality of said modules erected in the vertical disposition in alignment with one another in a row of said modules.

23. A solar array wall module as claimed in claim 22 wherein the row of said modules is one of a plurality of parallel rows together forming a solar wall farm.

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